Appabatus foe continuously



INVENTOR.

ATTORNEY.

1951 w. F. FABER APPARATUS FOR CONTINUOUSLY PRODUCING COMBUSTIBLE GAS Filed Feb. 10, 1945 ll. I. I HIIIIIJ T fl @3 3. FE EE-F Aug. 7, 1951 w. F. FABER APPARATUS FOR CONTINUOUSLY PRODUCING COMBUSTIBLE GAS 2 Sheets-Sheet 2 Filed Feb. 10, 1945 Fig. 5.

INVENTOR.

m7/'/&ah?"'f?"mer Patented Aug. 7, 1951 APPARATUS FOR CONTINUOUSLY PRODUCING COMBUSTIBLE GAS William F. Faber, Hillside, N. 1., assignor, by

mesne assignments, to David L.

Sherman,

Flushing, N. Y., as trustee Application February 10, 1945, Serial No. 577,304

1 Claim. 1

The invention relates to the manufacture of,

and apparatus for the production of a combustible gas for city gas use, from liquid or rich gaseous hydrocarbons, such as oil, butane, propane, refinery still gases or natural gases that unite or burn with oxygen. The invention has particular reference to the production of combustible gas by partial combustion and cracking of such fuels which'is supported and maintained by a supply of substantially pure free oxygen, or a mixture of oxygen-enriched air, or other oxygen mixtures with any inert gas, in which mixture the oxygen content by volume is for city gas preferably within a range of between 22 percent to 60 percent but which percentage range may be upwardly extended depending upon the quality of gas desired.

According to the invention, it is possible to produce a gas of a predetermined and substantially constant calorific value by a continuous process from fuel in a finely divided, vaporized, or gaseous state, for example, liquid hydrocarbons atomized by a stream of high velocity mixture of oxygen-enriched air. The speed of movement of the stream resulting from the mixture of the atomized liquid hydrocarbons and oxygen-enriched air is greater than its rate of flame propagation, thus preventing ignition at the point of initial mixing of said hydrocarbons and the oxygen-enriched air.

One of the objects of the invention is to produce a combustible fixed gas of predetermined calorific value and chemical constituency by the method and apparatus which involves the continuous, intimate and uniform mixing of the combustible fuel with a combustion-supporting gas, to wit, an oxygen-enriched air, in which combustion-supporting gas the total free oxygen content is preferably within a range of from 22 percent to 60 percent by volume, and effecting a partial or incomplete combustion while maintaining an established ratio of said combustible fuel and the combustion-supporting gas, thus converting the combustible fuel by partial combustion and the heat generated thereby, into a fixed combustible gas without production of carbon black while at the same time avoiding localized overheating detrimental to either the resulting end product or the gas generating apparatus.

The expression combustion-supporting gas" as well as the expression oxygen-enriched air" used herein is intended to indicate any mixture of substantially pure free oxygen and air, namely, from a 22 percent total free oxygen content to percent total free oxygen content by volume in the mixture. While a combustion-supporting gas having a concentration of greater than 60 percent free oxygen can be utilized for the process, carbon black is more likely to be formed when using a higher concentration than that 01' the preferable range specified.

When operating on a liquid fuel atomaed and mixed with an oxygen-enriched air having a, concentration of 56 percent oxygen and 44 percent nitrogen and/or inert gases, the process will produce a combustible fixed gas, when supplied with 4.5 gallons of said liquid fuel as follows:

mixed with an oxygen-enriched air having different oxygen concentration in the combustible mixture, the resulting combustible gas produced and the analyses thereof are as follows:

Percent of Oxygen in the Mixture from which the combustible gas is made 87% 56% 38% Carbon Dioxide C0 5.0 5. 5 6.0 Illuminants, 0.13,. e. 2 s. 1 12. 3 Oxygen, 0; 0. 6 0. 4 0.4 Carbon Monoxide, C0 37. 0 30. 6 24. 0 Hydrogen, Hl..-. 29.0 17. 8 6:3 Methane, CH4 18.2 l9.2 13.0 Nitrogen, N1 4. 0 18. 4 37. 5

B. t. uJcu. it. of gas made 540 540 540 Oil fuel used/MC]? of gas--- 4. 5 4. 5 4. 5 Specific Gravit 72 .79 Cu. it. of O; used/MCF of g 254 185 Cu. ft. of Air used/MCI of gas 50 233 475 As illustrating a specific form of the apparatus within and by which the invention is realized or embodied, reference is made to the accompanying drawings forming a part of this speciflcation.

In said drawings:

Fig. 1 shows in operative relationship certain instrumentalities or parts which may be employed in the realizing of the process and in the making up of an apparatus for performing the process.

Fig. 2 is a horizontal sectional view of a reaction chamber or gasification zone of a gas generator, taken on a plane indicated by line 2-2 of Fig. l.

Fig. 3 is a detailed drawing or a mixing device or burner for the atomization and mixing of liquid hydrocarbons, or for mixing of gaseous hydrocarbons with the oxygen-enriched air or combustion-supporting gas.

Fig. 4 is a vertical section of the mixing device and is a section taken on line 44 of Fig. 3.

Fig. 5 is an end view of the mixing device shown on Fig. 3.

Referring to the drawings in detail:

The gas generator proper I has a gas-tight metal shell 2 which in the main is sheet steel. The generator has a refractory inner wall or lining 3 and a heat insulating section 4 of such material as Sil-O-Cel brick, asbestos or other suitable insulating material. In the upper portion of the reaction chamber or gasification zone 5, there is provided a thermo-couple element 6 for measuring and controlling the predetermined reaction temperature by pyrometer 6 and control mechanism 6 which automatically operates a fuel valve l3. The reaction chamber is provided with an initial ignition or lighting port I equipped with valve 8 for inserting a torch for lighting up the'reaction chamber. In addition, the reaction chamber is provided with a refractory lined port 15 wherein the mixing device or burner I5 is located for introducing the mixture of combustible hydrocarbons and oxygen-enriched air to the reaction or gasiflcation chamber 5. A sight hole or port with valve 8* is provided in the upper portion of said chamber for the inspection of the heating-up operation. The gas making apparatus has an oil or fuel gas suction supply line 9, an oil or fuel gas pump in which delivers the hydrocarbon fuel to the control valve I3 and into the mixing device or burner l5 wherein the combustible fuel is atomized and/or mixed with the combustion-supporting gas from line 25, before delivery to port I! and into the reaction chamber.

Air is supplied to the gas generating apparatus by air pump i1 through line I8 provided with pressure regulator valve i9, to flow-meter 20 and control valve 2| which admits the volume of air desired to line 22 to the inlet of the heat exchanger jacket 23 (said jacket having continuous spiral baille or fin 23*), which preheats the air by the outgoing hot gases leaving the reaction chamber 5, by the heat conducted through the tube 34. The exit hot air passes from the heat exchanger through line 24 to a mixing point or zone 24 wherein there is received oxygen from the pressure supply line 26. The oxygen is controlled by regulator 21 whereby it is delivered at a constant pressure, and is fed at predetermined volume to flow-meter 29 from which it passes through valve 30 and line ll to the point or zone 24 wherein the oxygen .blends or mixes with the preheated hot air from line 24. The mixture of oxygen-enriched air flows through line 25 into the outer casing or body member l5 of the mixing device or burner I5 from which it flows at high velocity through an annular discharge port [5 provided within a ring-shaped burner tip I! and about a bulbshaped spud member li axially disposed with respect to the burner tip. The oil or fuel gas which is supplied through pipe 14 to the burner or mixing device I5 is delivered into fuelplD 4 section l5 which has a fuel distributing tip or multi-ported spud end member I 5 with port openings |5 from which the oil or fuel gas is directly delivered forcibly at right angles 'into the path of the oxygen-enriched air flowing at high velocity forwardly within an annular flowconstricting area about the spud while enroute to and through the burner discharge port 15 In this manner there is attained an effective atomization and/or intimate mixing of the oil or gaseous fuel and the oxygen-enriched air which forcibly engages and contacts the fuel projected thereinto. The thus atomized and/or mixed fuel and oxygen-enriched air is directed from the burner into a surrounding refractory tubular shield member l6 concentric with the burner and having a discharge port l5 where the refractory member it enters the reaction chamber or gasifying zone 5. The hot gases generated in chamber 5 pass out through off-take 32 and pipe 33 to heat exchanger tube 34 where part of its heat is given off by the cooling action 'of the air flowing through the heat exchanger jacket 23. The partially cooled gases pass from tube 34 to downcomer pipe 35 and flow through water sealed dip pipe 36 to cooler 38. Water is supplied for cooling the gases to room temperature by line 4| and control valve 42 which is regulated to give the desired pressure on dial guage 43. The water flows through lines 44 to spray nozzles 45 located in the said downcomer and cooler. The

downcomer pipe 35 is provided with a gas purge connection 46 and valve 41 and vent line 48 for purging the combustion gases during the heating-up period of the apparatus. It will be manifest, however, that the spent cooling water after passing through the sprays 45 to chamber 31 flows to the level-control point 49 and outlet 50 to seal pot 5| and drain 52 to sewer, or recovery basin as desired.

Mixing device or burner (Figs. 3 to 5) The mixing device or burner l5 employed in the apparatus of Fig. 1 is shown in detail in Figs. 3 to 5 and comprehends a hollow burner body l5 wherein the combustion-supporting gas flows to the burner discharge port I5 an oil or fuel tube It;' which is connected with and extends within the burner body to the port W. The fuel tube is provided with a, removable spud or multiple port li through which the fuel is delivered from its ports I5 and at right angles to the direction of flow of the fuel in the fuel tube l5 and also at right angles to the flow of the com bustion-supporting gas passing said spud or tip. The flow of fuel emerging from the spud ports 15 directly contacts the high velocity flow of the stream of the combustion-supporting gas passing the spud ports l5 and is immediately atomized by and/or mixed with the stream of combustionsupporting gas flowing enroute through a, tubular refractory member I5 providing the port I6 discharging into the reaction chamber 5. The combustible mixture discharged from the mixing device and entering the reaction chamber is ignited by the temperature of said chamber causing partial combustion and cracking of the fuel into fixed combustible gas. It will be noted that speed of flow of the stream of the combustible mixture at the burner nozzle port is greater than the rate of flame propagation for such combustible mixture, and is in the order of 300 to 800 feet per second, depending upon the content of oxygen in .the mixture for gasification. high velocity promotes high degree of atomization and/or mixing of the fuel with the combustion-supporting gas and moreover prevents combustion from occurring at the burner nozzle or parts thereof and protects such parts from overheating or melting.

In Fig. 4 there is shown a vertical section of the burner l5 taken on line 4--4 of Fig. 3. This section shows the position of the four metallic fins l5 provided on the fuel tube l5 for maintaining the fuel tube and spud li in a central position in the burner discharge port IS. The fins l5 are welded to the fuel tube and fit closely to the inner wall of the burner body so as to permit the fuel tube to be removed by disconnecting flange l5 for periodic inspection and cleaning. It is manifest that spud 15 can be adjusted for proper position in the nozzle l5 by the threaded connection on the fuel tube and spud.

Heating-up the gas generator To prepare the gas generator for gas making operation, the air pressure governor I9 is set for its proper pressure; the fuel pump relief valve or governor l is set for its proper pressure. The motor drive I! for the operation of the fuel pump and air pumps l0 and I! respectively, is started; water is supplied to the sprays 45 for the downcomer 35 and cooler 38, by opening valve 42 to the proper pressure shown on dial gauge 43. Purge valve 41 is opened for venting the combustion gases from the reaction chamber 5, during the heating-up period. Lighting port valve 8 is opened and a torch is inserted into the reaction chamber. Air from pump I1 is fed to the reaction chamber through burner 15, by opening valve 2| to a predetermined setting of flow shown on flow-meter 20. Fuel is fed to the burner 15 by opening hand dial valve I 4" to a predetermined setting of ,the dial. (Valves l2 and I3 are closed during the heating-up period.) The fuel passes through the fuel tube l5 of the burner to the distributing spud l5 to ports I5 where the jets of fuel emerge and contact the stream of high velocity air or combustion-supporting gas fed from line 25 and through the burner, causing atomization and/or mixing of the fuel with the combustion-supporting gas. The resulting mixture flows through port l6 and into the reaction chamber 5 wherein it is ignited by the torch and burns more or less completely and thus heats up the reaction chamber. The heating-up operation is continued and the torch removed when the temperature of the chamber attains about 600 degrees F., and the valve 8 is closed. The heating is thus iurther continued until the chamber at-- tains a temperature of about 1500 degrees F. at which point the gas generator is in readiness for gas making. The reaction chamber may be heated within a temperature range of 1300 F. to 1800 F. depending upon the quality of fuel used and the ratio of fuel to an air-oxygen mixture which will produce the desired quality of combustible city gas.

Gas making operation With the reaction chamber at a temperature of about 1500 degrees F. gas making may be commenced. Control pyrometer 6 is set to control and maintain the chamber temperature at 1500 degrees F. by means of thermo-couple 6 and leadwire connection 6*. The high-control-low circuit wires 6 operate the reversible motor in mechanism 6 and moves the operating levers 6 connected to the fuel control valve l3. If the temperature in the chamber falls slightly below the setting of the pyrometer target of 1500 degrees F., the contacts on the pyrometer cause the motor 6 to operate the lever mechanism 6 and cause the fuel valve I3 to close slightly, thus reducing the fuel flow to the burner l5 and chamber 5. On the other hand, if the temperature in the chamber rises slightly above the target setting, the pyrometer control mechanism automatically operates to open the valve I3 a slight amount. Moreover, when the temperature in the chamber corresponds to the target setting, th pyrometer is in control position, at which point no action occurs in the motor mechanism; thus the setting of valve l3 remains stationary until the chamber temperature differs from the target setting.

Therefore, with the above points in mind, the gas making operation is carried out directly after the above mentioned heating-up operation, as follows: Fuel shut-off valve 12 is opened wide (valve 13 is already opened and adjusted for its predetermined setting). The dial fuel valve I4 is closed. Air control valve 21 is adjusted to produce the desired flow rate on flow-meter 2|]. Oxygen valve is gradually opened until the desired predetermined flow is attained on the oxygen flow-meter 29, thus supplying the process with oxygen-enriched air. The air and oxygen is mixed at point 1M as it flows to the burner l5 through which said oxygen-enriched air forwardly flows and atomizes and/or mixes with the fuel flowing from the fuel spud I5 at the ports I55 The resulting combustible mixture of fuel and oxygen-enriched. air flows from the burner nozzle at a speed greater than its rate of flame propagation, said combustible mixture continues to flow through port I6 and into the reaction chamber 5 wherein the mixture is ignited by the temperature therein, causing partial combustion and cracking of the fuel into fixed combustile gases as a result of partial combustion and the heat generated thereby without supplying external heat. Purge valve 41 is now closed causing the resultant combustile gases to flow from the chamber 5 and through off-take 32 to the heat exchanger tube 34 where part of the heat in the hot gases in the tube 34 is transferred to the incoming air used for the process, flowing through the-heat exchanger jacket 23. The combustile gases flow from the heat exchanger to the downcomer pipe 35 and contact the initial water cooling spray 45; said gases pass through dip pipe 36 and through water seal 35 and upward through skirt 35 to cooler 38 in contact with the water from spray 45 in said cooler, while flowing upwardly through the wetted wood grids thus cooling the gases prior to their discharge through the cooler outlet pipe 40 where the gases pass to the usual gas cleaning or detarring equipment, such as the well known electrical precipitators or shavings scrubbers for the removal of condensates and other impurities, ready for storage or consumption as city gas.

What I claim is:

Apparatus for continuously producing combustible gas of about 540 B. t. u. suitable for city use comprising a reaction chamber having a discharge outlet in the upper portion thereof and a tangentially disposed fuel inlet adjacent the bottom thereof and communicating with the interior of the reaction chamber, an elongated fuel, air-oxygen mixing device including concentrically arranged feed conduits for fuel and heated air-oxygen, both of which conduits terminate at the inner end of the mixing device and form a nozzle structure, the nozzle structure being disposed in the tangential opening and spaced considerably outwardly of the reaction chamber thus serving to shield the nozzle from the burning fuel in the chamber, a heat exchanger exteriorly of, remote from the chamber and connected by a conduit with the chamber discharge, conduit means for supplying air to the heat exchanger, conduit means for supplying heated air from the heat exchanger to the outer of the conduits of the mixing device, a separate oxygen conduit supplying means connected to the heated air supplying conduit intermediate the heat exchanger and a mixing device for feeding air-oxygen to the outer conduit of the mixing device and nozzle structure, and a fuel supply conduit connected to the inner conduit of the mixing device for feeding fuel to the mixing device and the nozzle structure, means for controlling the supply of air and oxygen to the outer conduit of the mixing device, control means responsive to the temperature within the reaction chamber to control the amount of fuel supplied to the inner conduit of the mixing device, the control means for the supply of fuel, air and oxygen being so correlated to supply the fuel, air and oxygen in proper ratios to each other to produce a gas of the required B. t. u., and the control means for the fuel supply when actuated serving to supply varying amounts of fuel to the mixing device depending upon the temperature of the reaction chamber to maintain the temperature range of the reaction chamber between 1300 F. and 1800 1''.

WILLIAM F. FABER.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,229,338 Sklovsky June 12, 1917 1,340,902 Lundgaard May 25, 1920 1,490,921 Godward Apr. 22, 1924 1,694,910 Bassett Dec. 11, 1928 1,698,525 Bassett Jan. 8, 1929 1,724,097 Losack Aug. 13, 1931 1,830,574 'I'hwing Nov. 3, 1931 1,966,610 Chilowsky July 17, 1934 1,971,728 Perry Aug. 28, 1934 1,992,909 Davis Feb. 26, 1935 2,011,034 Chilowsky Aug. 13, 1935 2,085,584 Haskell June 29, 1937 --FOREIGN PATENTS Number Country Date 147,100 Switzerland Aug. 1, 1931 300,328 Great Britain Nov. 15, 1928 tice, pp. 620 to 624, 648 to 651.

Haslam et al., Fuels and Their Combustion," page 226. 

